Service Manual Chassis, Mast & Options EP10KRT EP12KRT EP15KRT
ETB10-00011-up ETB10-20001-up ETB10-50001-up
99759-65110
GROUP INDEX GROUP INDEX
Items involved
GENERAL INFORMATION
Serial Number Locations, Dimensions, Technical Data
1
VEHICLE ELECTRICAL COMPONENTS
Console Box, Key Switch, Lamp Specification Chart
2
MAIN CONTROLLER
Outline, Controller Components, Logic Card Components, Controller Models, Operation Outline, Drive System, Hydraulic System, Fail-safe System, Malfunction Detection, Malfunction Data Record, Setting, Self-diagnosis, etc.
3
TROUBLESHOOTING FOR CONTROL CIRCUITS
Faulty Central Vehicle Monitor System, Faulty Diagnosis Indication, or Other Abnormalities
4
MOTORS
Motor Installation Positions, Specifications, Structures, Tightening of High-power Cable Terminals, Inspection of Brushes for Wear and Brush Replacement, Procedures and Key Points for Removal and Installation, etc.
5
FRONT AXLE
Structure and Functions, Disassembly and Reassembly of Front Axle Assembly, Service Data
6
REAR AXLE
Rear Axle, Rear Wheels, Removal and Installation, Disassembly and Reassembly, Adjustment, Troubleshooting, Service Data
7
BRAKE SYSTEM
Specifications, Structure and Functions, Procedures and Key Points for Disassembly and Reassembly, Inspection and Adjustment, Troubleshooting, Service Data
8
STEERING SYSTEM
Specifications, Structure and Functions, Procedures and Key Points for Removal and Installation, Steering Control Valve, Hydraulic Circuit, Troubleshooting, Service Data
9
HYDRAULIC SYSTEM
Tank, Pump, Control Valve, Lift and Tilt Cylinders, Flow Regulator Valve, Down Safety Valve
10
MASTS AND FORKS
Simplex Mast, Duplex Mast, Triplex Mast
11
SERVICE DATA
Inspection Standards, Periodic Replacement of Parts, Lubrication Standards, Main Component Weights, Tightening Torque for Standard Bolts and Nuts, Special Tools
12
OPTIONS
Amber Strobe Kit, Back Buzzer Kit, Working Lamp Kit, Tire Kit
13
GENERAL INFORMATION 1 Vehicle Exterior ....................................................................................... Models ....................................................................................................... Serial Number Locations ...................................................................... Chassis and Mast Model Identification ............................................ Dimensions .............................................................................................. Technical Data .........................................................................................
1–1 1–1 1–2 1–3 1–4 1–5
GENERAL INFORMATION
Vehicle Exterior
103378
Models This manual applies to EP10KRT, EP12KRT and EP15KRT.
Truck Model
Serial Number
EP10KRT
ETB10-00011-up
EP12KRT
ETB10-20001-up
EP15KRT
ETB10-50001-up
1-1
GENERAL INFORMATION
Serial Number Locations
Mast number
Chassis number
Nameplate
209010
1-2
GENERAL INFORMATION
Chassis and Mast Model Identification
[Chassis] EP
10
KRT
Generation designator and truck type
Rated capacity 10: 1000 kg 12: 1250 kg 15: 1500 kg Battery type GP: gasoline engine DP: diesel engine [Mast] 2
G
15
CA
33
Maximum lifting height “33” stands for 3300 mm Order of the minor change (“CA” for the original, “CB” for the first change, “CC” for the second change, and so on) Applicable truck model designation 15: 1.0 ton class
Kind of mast G: simplex mast H: duplex mast J: triplex mast Major change (“2” for the original, “3” for the first change, and so on up to “9”)
1-3
GENERAL INFORMATION
Dimensions
209011
1-4
GENERAL INFORMATION
Technical Data Truck model
EP10KRT
EP12KRT
EP15KRT
Mast tilt, forward/backward
A (deg)
5/7
5/7
5/7
Height with mast lowered
B (mm)
2110
2110
2110
Standard free lift
C (mm)
120
120
120
Standard lift height
D (mm)
3300
3300
3300
3895
3895
3895
Overall height with mast raised (without backrest) E (mm) Overall length
F (mm)
2500
2500
2575
Length to fork face (includes fork thickness)
G (mm)
1700
1700
1775
Overall width
H (mm)
997
997
997
Forks dimensions (thickness × width × length)
I (mm)
35 × 80 × 800
35 × 80 × 800
35 × 80 × 800
Turning circle radius
J (mm)
1370
1370
1445
Fork carriage width
K (mm)
920
920
920
Ground clearance under mast, with load
L (mm)
80
80
80
100
100
100
Ground clearance center of wheelbase, with load M (mm) Travel speed, with/without load
km/h
11.5/13.5
11.2/13
11/12.5
Lifting speed, with/without load
m/s
0.29/0.48
0.27/0.48
0.26/0.48
Lowering speed, with/without load
m/s
0.52/0.50
0.52/0.50
0.52/0.50
1569/1667
1520/1669
1470/1670
4217/4315
4168/4315
4119/4314
Rated drawbar pull, with/without load (60 min. short duty)
N
Maximum drawbar pull, with/without load (5 min. short duty)
N
Gradeability, with/without load
%
5.5/8
4.5/7.5
3.5/6.5
Maximum gradeability, with/without load
%
13/20
11/18
10/16
Battery to DIN 43531/35/36A/B/C/No. Battery voltage/capacity at 5-hour discharge
DIN43535A V/Ah
Battery weight
kg
Truck weight, without load/including battery (Maximum battery)
kg
24/600, 720
24/600, 720
24/720, 840
445, 540
445, 540
540, 620
2333
2568
2778
Drive motor capacity (60 min. short duty)
kW
4.8
4.8
4.8
Pump motor output @15 % duty factor
kW
8.8
8.8
8.8
Drive motor control method
Mosfet-chopper
Pump motor control method
Chopper
1-5
Thank you very much for your reading. Please Click Here Then Get More Information. NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
VEHICLE ELECTRICAL COMPONENTS Console Box ............................................................................................. 2 – 1 Functions of Vehicle Monitor System ........................................................ 2 – 1 Electrical Components .............................................................................. 2 – 3 Disassembly and Reassembly .................................................................. 2 – 4
Direction Lever ........................................................................................ Accelerator Control ............................................................................... Key Switch ............................................................................................... Lighting Switch ....................................................................................... Fuses ......................................................................................................... Lamp Specification Chart .................................................................... Electrical System Diagram (Type: Chopper) ................................... Electrical Schematic (Type: Chopper) .............................................. Electrical Schematic (Type: Chopper) ..............................................
2– 5 2– 6 2– 7 2– 7 2– 8 2– 8 2– 9 2 – 11 2 – 13
2
VEHICLE ELECTRICAL COMPONENTS
Console Box 1 2 3 4
Vehicle monitoring system (VMS) Steering tilt knob Key switch Lighting switch
103380
Functions of Vehicle Monitor System (VMS)
209140C
Operations
No.
Monitor name
1
Service indicator
2
Worn motor brush Drive motor and pump motor Worn brushes lamp brushes in operable condition
After brushes are replaced, lamp turns OFF.
3
Service indicator Controller, drive motors and Overheat pump motor in normal temperature
Error code is indicated on display 8 when overheating condition has occurred.
4
Remaining battery charge warning lamp
5
Brake fluid level lamp
6
Parking lamp
When OFF
When ON or flashing
Remarks
Wrench-symbol warning lamp turns on when error has occurred.
Normal battery condition
Red LED turns on. Drive 1: Lifting function operates in restricted mode. Normal fluid level
Parking brake disengaged
Parking brake engaged 2-1
Low fluid level
VEHICLE ELECTRICAL COMPONENTS
No. 7
Monitor name
When OFF
Malfunction lamp Normal
Vehicle malfunction
Any of four green LEDs turns on when corresponding battery is discharged.
Battery discharge indicator (BDI)
9
10
Hourmeter time display
11
Truck mode indicator
Remarks
Error code is displayed as follows when an error is present. A L × × ×
Error indicator
8
When ON or flashing
Power mode (Mode B)
Economy mode (Mode A)
Error indicator
Indication
Condition
A L 0
7
9
ON
Key switch turned [ON] with direction lever in [F] or [R] position
A L 0
6
5
ON
Drive motor overheated
A L 0
1
7
ON
Pump motor overheated
A L 0
6
2
ON
Traction controller overheated
A L 0
0
6
ON
Data communication error
A L 0
3
5
ON
Pump motor overcurrent
A L 0
6
4
ON
Hydraulic controller overheated
A L 0
7
2
ON
Drive motor stall timer
A L 0
7
9
ON
Faulty setting of tilt lever
A L 0
7
9
ON
Faulty setting of attachment lever 1
A L 0
7
9
ON
Faulty setting of attachment lever 2
A L 0
3
2
ON
Regeneration diode error
A L 0
3
2
ON
Drive motor armature diode error
A L 0
2
8
ON
Pump motor armature diode error
A L 0
6
9
ON
Drive motor armature overcurrent
A L 0
5
7
ON
Drive motor field overcurrent 2-2
VEHICLE ELECTRICAL COMPONENTS
Electrical Components
209141
1 2 3 4
Key switch Display Horn Controller
5 6 7 8
2-3
Contactor Fuse holder Plate Rivet
VEHICLE ELECTRICAL COMPONENTS
Disassembly and Reassembly Disassembly
209142
Sequence 1 2
Console box (front panel) Forward/reverse lever
3 4
Console box (rear panel) Steering column assembly
Disassembly procedure (1) Remove the rear panel and front panel from the steering column assembly. (2) Disconnect the harness connector at the direction lever. (3) Disconnect the harness connector at the horn. (4) Remove the steering tilt knob from the rear panel of the console box. (5) Remove the steering column assembly. 209143
Reassembly Follow the disassembly procedure in reverse.
2-4
VEHICLE ELECTRICAL COMPONENTS
Direction Lever Structure
209144
1 2 3
Knob Lever Harness
4 5
2-5
Connector Screw, Spring washer